2005 SUZUKI SWIFT gear

Downloaded from www.Manualslib.com manuals search engine 1D-5 Engine Mechanical:
11) Connect negative cable at battery.
12) Install special tools (Compression gauge) into spark plug hole.
Special tool
(A): 09915–64512
(B): 09915–64530
(C): 09915–67010
13) Disengage clutch (1) (to lighten starting load on engine) for M/T vehicle, and depress accelerator
pedal (2) all the way to make throttle fully open.
14) Crank engine with fully charged battery, and read the highest pressure on compression gauge.
NOTE
• For measuring compression pressure, crank engine at least 250 r/min. by using
fully charged battery.
• If measured compression pressure is lower than limit value, check installation
condition of special tool. If it is properly
installed, possibility is compression
pressure leakage from where piston ring
and valve contact.

Compression pressure
Standard: 1400 kPa (14.0 kg/cm2, 199.0 psi)
Limit: 1100 kPa (11.0 kg/cm2, 156.0 psi)
Max. difference between any two cylinders: 100
kPa (1.0 kg/cm
2, 14.2 psi) 15) Carry out Steps 12) through 14) on each cylinder to
obtain 4 readings.
16) Disconnect negative cable at battery.
17) After checking, install spark plugs and ignition coil assemblies (2) with high-tension cord (3).
18) Connect ignition coil couplers (1).
19) Connect fuel injector wires (4) at the coupler.
20) Install cylinder head upper cover.
21) Install air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
22) Install engine cover.
23) Connect negative cable at battery.
Engine Vacuum CheckS7RS0B1404002
The engine vacuum that develops in the intake line is a
good indicator of the condition of the engine. The
vacuum checking procedure is as follows:
1) Warm up engine to normal operating temperature.
NOTE
After warming up engine, be sure to place
transaxle gear shift lever in “Neutral”, and set
parking brake and block drive wheels.

2) Stop engine and turn off the all electric switches.
3) Remove engine cover.
4) Remove air cleaner assembly and air suction hose referring to “Air Cleaner Components”.
5) Remove PCV hose (1) from PCV valve (2).
(A)
(C)
(B)
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Downloaded from www.Manualslib.com manuals search engine 1D-17 Engine Mechanical:
Engine Assembly Removal and InstallationS7RS0B1406011
NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative and pos itive cable at battery.
3) Remove battery and tray.
4) Remove engine hood after disconnecting windshield washer hose.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to “Compressor Drive Belt Remo val and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil, transaxle oil and coolant.
8) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
9) Remove air cleaner assembly referring to “Air Cleaner Components”.
10) With hose connected, detach A/C compressor from its bracket (A/C model) referring to “Compressor
Assembly Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

11) Remove intake manifold rear stiffener (1) from intake manifold and cylinder block. 12) Disconnect the following electric wires:
• MAP sensor (1)
• ECT sensor (2)
•EGR valve (3)
• CMP sensor (4)
• Electric throttle body assembly (5)
• Ignition coil assembly (6)
• Injectors (7)
• Heated oxygen sensor No. 2 (8) and No. 1 (9)
• Oil control valve (10)
• Engine oil pressure switch (11)
• CKP sensor (12)
• Knock sensor (13)
• Back up light switch (14)
• Generator (15)
• Starting motor (16)
• Ground terminal (17) from intake manifold
• Battery ground terminal (18) from exhaust manifold
• Battery ground cable (19) from transaxle
• Magnet clutch switch of A/C compressor (A/C model)
• Each wire harness clamps
• Output shaft speed sensor (VSS) (34) (A/T model)
• Solenoid valve (33) (A/T model)
• Transmission range sensor (32) (A/T model)
• Input shaft speed sensor (31) (A/T model)
13) Remove fuse box from its bracket.
14) Disconnect the following cables: • Gear select control cable (23) (M/T model)
• Gear shift control cable (24) (M/T model)
• A/T select cable (A/T model)
15) Disconnect the following hoses: • Brake booster hose (26) from intake manifold
• Radiator inlet and outlet hoses (20) from each pipe
• Heater inlet and outlet hoses (21) from each pipe
• Fuel feed hoses (22) from fuel feed pipe
• EVAP canister purge valve hose (30) from purge pipe
• A/T fluid cooler hoses (A/T model)
16) With hose connected, detach clutch operating cylinder (25). (M/T model)
CAUTION!
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.

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Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-18
17) Disconnect right and left drive shaft joints from differential gear referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
NOTE
For engine and transaxle removal, it is not
necessary to remove drive shafts from
steering knuckle.

18) Remove exhaust No.1, No.2 and center pipes referring to “Exhaust Pipe and Muffler Removal and
Installation in Section 1K”.
19) Support engine assemble by using chain hoist.
20) Remove suspension frame referring to “Front Suspension Frame, Stabiliz er Bar and/or Bushings
Removal and Installati on in Section 2B”.
21) Remove engine rear mounting from engine rear mounting No.1 bracket.
22) Support engine and transaxle with jack, and then remove chain hoist.
23) Remove engine left mounting bracket nuts (1) and engine right mounting nuts (2).
[A]: M/T model
[B]: A/T model
7
26
30
5
4
22
3
2
20
6
9
18
8
11
10
21 1
16
17
151213
[B]
23
24
14
25 19
34
33
32
32
31
[A]
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Downloaded from www.Manualslib.com manuals search engine 1D-63 Engine Mechanical:
Main Bearing Cap No.1 Bolt
Measure each thread diameter main bearing cap No.1
bolts (1) at “A” on 60 mm (2.36 in.) from seat side of
flange bolt and “B” on 90 mm (3.54 in.) from seat side of
flange bolt by using a micrometer (2).
Calculate difference in diameters (“A” – “B”).
If it exceeds limit, replace with new one.
Main bearing cap No.1 bolt diameter measurement
points
“a”: 60 mm (2.36 in.)
“b”: 90 mm (3.54 in.)
Main bearing cap No.1 bolt diameter difference
Limit (“A” – “B”): 0.2 mm (0.008 in.)
Sensor Plate InspectionS7RS0B1406039
Check sensor plate for crack damage.
If malcondition is found, replace it.
Rear Oil Seal InspectionS7RS0B1406040
Carefully inspect oil seal (1) for wear or damage. If its lip
is worn or damaged, replace it.
Flywheel InspectionS7RS0B1406041
Visual Inspection
• If ring gear is damaged, cracked or worn, replace flywheel.
• If the surface contacting cl utch disc is damaged, or
excessively worn, replace flywheel.
Flywheel Face Runout
Check flywheel face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel face runout
Limit: 0.2 mm (0.0079 in.)
Cylinder Block InspectionS7RS0B1406042
Distortion of Gasketed Surface
Using straightedge and thickness gauge, check
gasketed surface for distortion and, if flatness exceeds
its limit, correct It.
Cylinder block flatness
Limit: 0.03 mm (0.0012 in.)

“A”
“a” “b” “B”

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Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-3
6) Start engine and warm engine up to normal operating temperature.
NOTE
Be sure to shift transaxle gear shift lever in
“Neutral” (shift select lever in “P” range for
A/T vehicle), set parking brake and block
drive wheels.

7) After warming up, raise engine speed to 4,000 r/min. and measure oil pressure.
Oil pressure specification
More than 270 kPa (2.7 kg/cm2, 39.8 psi) at 4,000
r/min. (rpm)
8) After checking oil pressure, stop engine and remove oil pressure gauge and attachment.
9) Before reinstalling oil pressure switch (2), be sure to
wrap its screw threads with sealing tape (1) and
tighten switch to specified torque.
NOTE
If sealing tape edge is bulged out from screw
threads of switch, cut it off.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft) 10) Start engine and check oil pressure switch for oil
leakage. If oil leakage is found, repair it.
11) Connect oil pressure switch coupler (1).
Repair Instructions
Heat Exchanger ComponentsS7RS0B1506001
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4
5
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1. Heat exchanger inlet No. 1 hose 4. Gasket7. O-ring
: Apply engine oil.
2. Heat exchanger outlet No. 1 hose 5. Heat exchanger stand bolt : 22 N⋅m (2.2 kgf-m, 16.0 lb-ft)
3. Heat exchanger 6. Oil filter adapter case : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine 1G-3 Fuel System:
4) Check that battery voltage is 11 V or more.
5) Measure fuel pressure at each condition.If measured pressure is out of specification, refer to
“Fuel Pressure Check in Section 1A” and check each
possibly defective part. Replace if found defective.
a) Turn ignition switch ON to operate fuel pump and after 2 seconds turn it OFF. Repeat this 3 or 4
times and then check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine
stopped: 270 – 310 kPa (2.7 – 3.1 kg/cm2, 38.4
– 44.0 psi)
b) Start engine and warm it up to normal operating temperature, and measure fuel pressure at
idling.
Fuel pressure specification
At specified idle speed: 270 – 310 kPa (2.7 –
3.1 kg/cm2, 38.4 – 44.0 psi)
c) Stop engine, and measure fuel pressure at one minute after stopping.
Fuel pressure specification
With 1 min. after engine (fuel pump) stop
(Pressure reduces as time passes): Over 300
kPa (3.0 kg/cm
2, 42.7 psi)
6) After checking fuel pressure, remove fuel pressure gauge.
WARNING!
As fuel feed line is still under high fuel
pressure, make sure to release fuel pressure
according to the following procedures.
• Place fuel container under joint.
• Cover joint with rag and loosen joint nut slowly in order to release fuel pressure
gradually.

7) Remove special tools from fuel delivery pipe and fuel feed hose.
8) Connect fuel feed hose to fuel delivery pipe and clamp it securely.
9) With engine OFF and ignition switch ON, check for fuel leaks.
Fuel Cut Operation InspectionS7RS0B1704002
NOTE
Before inspection, make sure that gear shift
lever is in neutral positi on (shift select lever
is “P” range for A/T vehicle), A/C is OFF and
parking brake lever is pulled all the way up.

1) Warm engine up to normal operating temperature.
2) While listening to sound of injector (2) by using sound scope (1) or such, increase engine speed to
higher than 3,000 r/min.
3) Check to make sure that injector operation sound is stop when throttle valve is closed instantly and it is
heard again when engine speed is reduced to
approx. 2,000 r/min or less.
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Downloaded from www.Manualslib.com manuals search engine 1G-7 Fuel System:
Fuel Pressure Relief ProcedureS7RS0B1706003
CAUTION!
This work must not be done when engine is
hot. If done so, it may cause adverse effect to
catalyst.

NOTE
If ECM detects DTC(s) after servicing, clear
DTC(s) referring to “DTC Clearance in
Section 1A”.

1) Make sure that engine is cold.
2) Shift transaxle gear shift lever in “Neutral” (shift select lever in “P” range for A/T model), set parking
brake and block drive wheels.
3) Remove relay / fuse box cover.
4) Disconnect fuel pump relay (1) from relay / fuse box (2).
5) Remove fuel filter cap in order to release fuel vapor pressure in fuel tank, and then reinstall it.
6) Start engine and run it until engine stops for lack of fuel. Repeat cranking engine 2 – 3 times for about 3
seconds each time in order to dissipate fuel pressure
in lines. Fuel connections are now safe for servicing.
7) After servicing, connect fuel pump relay (1) to relay / fuse box and install re lay / fuse box cover.
Fuel Leakage Check ProcedureS7RS0B1706004
After performing any service on fuel system, check to
make sure that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump) and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply
fuel pressure to fuel line until fuel pressure is felt by
hand placed on fuel feed hose.
2) In this state, check to see that there are no fuel leakages from any part of fuel system.
Fuel Lines On-Vehicle InspectionS7RS0B1706005
CAUTION!
Due to the fact that fuel feed line (1) is under
high pressure, use special care when
servicing it.

Visually inspect fuel lines for evidence of fuel leakage,
hose crack and deterioration or damage.
Make sure all cl amps are secure.
Replace parts as needed.
Fuel Pipe Removal and InstallationS7RS0B1706006
WARNING!
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” in order to reduce the risk or fire
and personal injury.

Removal
1) Relieve fuel pressure in fuel feed line according to “Fuel Pressure Relief Procedure”.
2) Disconnect negative cable at battery.
3) Disconnect fuel pipe joint and fuel hose (3) from fuel pipe (2) at the front and rear of each fuel pipe
referring to “Fuel Hose Disconnecting and
Reconnecting”.
4) Mark the location of clamps (1) on fuel pipes (2), so that the clamps can be reinstalled to where they
were.
5) Remove pipes (2) with clamp (1) from vehicle.
6) Remove clamp (1) from pipes (2).
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Downloaded from www.Manualslib.com manuals search engine 1H-8 Ignition System:
Ignition Coil Assembly (Including ignitor)
Removal and Installation
S7RS0B1806005
Removal1) Disconnect negative (–) cable at battery.
2) Remove air cleaner assembly with air intake pipe and cylinder head upper cover.
3) Disconnect ignition coil coupler.
4) Disconnect high-tension cord (3) from ignition coil assembly (2).
5) Remove ignition coil bolts (1) and then pull out ignition coil assembly.
Installation 1) Install ignition coil assembly (2).
2) Tighten ignition coil bolts (1) to specified torque, and then connect igni tion coil coupler.
Tightening torque
Ignition coil bolt (a): 10 N·m (1.0 kgf-m, 7.5 lb-ft)
3) Install high-tension cord (3) to ignition coil assembly while gripping its cap.
4) Install cylinder head upper cover and air cleaner assembly with air intake pipe.
5) Connect negative (–) cable to battery.
Ignition Coil Assembly (Including ignitor)
Inspection
S7RS0B1806006
Measure secondary coil for resistance.
If resistance is out of specification, replace ignition coil
assembly.
Secondary coil resistance
7.5 – 10.3 k Ω at 20 °C, 68 ° F
Ignition Timing InspectionS7RS0B1806007
NOTE
• Ignition timing is not adjustable. If ignition
timing is out of specification, check
system related parts.
• Before starting engine, place transmission gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T model), and set
parking brake.

1) Connect scan tool to DLC (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
2) Start engine and warm it up to normal operating temperature.
3) Make sure that all of electrical loads except ignition are switched off.
4) Check to be sure that idle speed is within specification referring to “Idle Speed and IAC
Throttle Valve Opening Inspection in Section 1A”
5) Fix ignition timing by using “Fixed Spark” of “Misc Test” mode on scan tool.
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